Six axis motion control apparatus

ABSTRACT

A motion control apparatus for measuring and scanning an object. The motion control apparatus includes a base. The motion control apparatus also includes an object support assembly that is coupled to the base. The object support assembly receives the object to be scanned and measured. The motion control apparatus includes a scanner track that extends above from the base. The scanner and object are moveable about multiple axes to position to the scanner with respect to the object for viewing the object by the scanner for obtaining measurements of the object.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable

STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT

Not Applicable

BACKGROUND

1. Field of the Invention

The present invention relates to a motion control apparatus and moreparticularly to a six axis motion control apparatus for non-contactscanning of a surface of an object.

2. Description of the Prior Art

Three dimensional scanning is an important component associated with themanufacturing process. Optical three dimensional scanning is accurateand a cost-effective alternative delivering more dimensional informationto aid in quality control and process optimization. The ability toprovide the designed geometry to meet the designer's intent and achievethe engineering dimensional requirement to deliver the intended fit andfunctionality is an ongoing challenge during the manufacturing process.Optical three dimensional scanning is based on the principle oftriangulation. A sensor unit projects different fringe patterns onto anobject to be measured. These patterns may then be recorded by twocameras. Based on the optical image equations, a computer mayautomatically calculate the three dimensional coordinates. In order todigitally render the object completely, several individual measurementsfrom various views are required. After scanning is completed, a softwareprogram may be used to calculate a complete high-resolution polygon meshof the object surface, creating small triangles in curved and largetriangles in flatter areas without diminishing the mesh's accuracy.

Traditionally, in a first article inspection, an inspection plan iscreated based on the CAD data. This plan defines the features to bemeasured and their corresponding tolerances. For complex parts, severalhundred features may need to be measured. The task of measuring thesefeatures can be time-consuming with a tactile measuring device. Evenafter the measuring is complete and the report is generated it is stilldifficult to identify the problematic areas and determine correctiveaction due to the lack of full part information. A new procedure is madepossible with the use of a white light volumetric scanner which may beused to create and complete a test plan. The first article of inspectionprocess is expedited via the use of full-field scanning and using fullcolor plot images.

In order to measure, assess and document the inspection of numerousidentical parts during sampling checks, production ramp-up and forproduction control, two additional components are required: a handlingdevice for the sensor or the component and a macro recorder in thesoftware for the automation of measurements, data evaluation, protocolgeneration and output. The ability to speed the production of a broadrange of manufactured parts (from engines to medical devices) isdesired.

To obtain a three dimensional scan of a surface of an object, thescanner may be held by an individual. The individual may then beginscanning the surface of the object from a variety of differentperspectives and angles to achieve a comprehensive scan of the object.However, scanning and measuring an object by having an operator holdingthe scanner is tedious, time consuming, and not conducive to repetition.To overcome some of the issues associated with using the scanner, thescanner may be placed on a tripod. The tripod configuration stillrequires manual movement of the scanner by an operator. But the tripodmay improve the operator's ability to repeat certain positions withlittle discrepancy from past measurements. The problem with using atripod is the limits of various perspectives that are achieved whenscanning an object. Typically, for each new scan, the scanner must berepositioned. To address these problems manufacturers may use variousdevices that enable some automatic component repositioning.Unfortunately, the scan of the object or work piece with these devicesmay produce undesired shadows, making completely automated scanning lessfeasible.

An improved method of obtaining a three dimensional scan involves theuse of a coordinate measuring machine (CMM). The CMM may be manuallycontrolled by an operator or computer controlled. A typical CMM may becomposed of three different axes that are orthogonal to each other. Eachaxis has a very accurate scaling system that indicates the preciselocation of that axis. Using a CMM device is more accurate and resultsin faster scanning times than a three dimensional scan using a handheldscanner. CMM devices may be combined with white light volumetricscanner's that provide laser scanning. Laser scanning uses laser beamsthat are projected against the surface of the object to be scanned.Thousands of points are taken and used to validate size and position ofthe object and to create a three dimensional image of the object. Datais generated and transferred to CAD software to create a threedimensional model of the object. However, even with the technologicaladvances associated with CMM devices, collecting measurement data andmanual inspection techniques are very time consuming.

Non-contact scanning systems known in the art may be used to reduce thetime required for a three dimensional scan and measurement of an object.As understood, one such non-contact scanning system provides a morecomprehensive scan than a three dimensional scan using conventional CMMdevices, tripods, or manual operation. The non-contact scanning systemprovides automation that allows for repeat scanning of similar objectsfor accuracy. Unfortunately, these scanners may be limited with respectto some of its movements. This may result in less comprehensive scansand measurements of the object with respect to certain perspectives.

Accordingly, there exists a need in the art for a motion controlapparatus enabling non-contact three dimensional scanning whichaddresses one or more of the deficiencies identified above, known in theart or discussed below.

BRIEF SUMMARY

A motion control apparatus for non-contact three dimensional scanning ofa surface of an object is provided. The motion control apparatus uses acomputer and associated software to automate the measurement of theobject to be scanned. The ability to automate scanning of the objectproduces more accurate, faster, and comprehensive results. The motioncontrol apparatus is used to automate the measurement process for smallto mid-size parts. The motion control apparatus is configured to recorda measurement plan used to measure the object being scanned. Using themeasurement plan, the motion control apparatus is able to repeat theprocess over and over much quicker than is manually possible by anoperator. The motion control apparatus may measure each object inprecisely the same way by using the repetitive process of the machine,eliminating the human variability of the operators. The motion controlapparatus uses precision engineered servo motors and stages tofacilitate movement of the object to be scanned and a scanner forobtaining a plurality of views and perspectives of the object that ismeasured.

The motion control apparatus includes at least three tracks for linearmovement of an object support assembly and a white light volumetricscanner. The tracks may use servo motors, stages, belts, hydraulics,pneumatics, or any other well known technology to move the objectsupport assembly that carries the object to be scanned and the scanner.In addition to linear movement, the object support assembly isconfigured to rotate between 0 and 360 degrees such that the object maybe scanned and measured from various perspectives. The scanner is alsoconfigured to rotate about an axis defined by a scanner line of sight.The object support assembly may also be configured to pivot about anaxis that is parallel to the linear movement associated with at leastone of the tracks. The scanner may also be configured to pivot about anaxis that is parallel to the linear movement associated with at leastone of the tracks.

In further detail, a first embodiment of the motion control apparatus isdescribed. The motion control apparatus includes a base used to supportthe various tracks that allow for linear movement relative to the base.The base portion is used to provide the support necessary for carryingan object or a work piece to be scanned and measured. The motion controlapparatus also includes an object support assembly that is coupled tothe base. The object support assembly receives the object to be scannedand measured. The object support assembly is linearly movable parallelto at least two axes. The object support assembly is also rotatableabout a third axis. The three axes about which the object supportassembly is movable are all orthogonal to each other.

The motion control apparatus also includes a scanner track that extendsvertically from the base. The scanner track has a proximal end and adistal end. The proximal end of the scanner track is attached or coupledto the base portion of the motion control apparatus. The distal end ofthe scanner track extends away from the base. However, the scanner trackmay be removed from the base to enable enhanced portability of themotion control apparatus. The motion control apparatus also includes ascanner which is coupled to the scanner track. The scanner track definesa longitudinal axis where the scanner is linearly movable parallel tothe longitudinal axis. The scanner also defines a line of sight axis.The line of sight axis extends from the scanner to a point on the objectto be scanned. In this regard, the line of sight axis may extendlinearly. The scanner is configured to rotate about the line of sightaxis. The scanner is coupled to the scanner track using a bracket. Thescanner is pivotably coupled to the bracket at a first and a second sideof the scanner. The scanner defines a pivot axis which extendshorizontally from the first side of the scanner to the second side ofthe scanner and is orthogonal to the longitudinal axis. The scanner isconfigured to pivot about the pivot axis.

The motion control apparatus may further include a pair of spaced aparttracks. The pair of spaced apart tracks are coupled to the base. Thepair of spaced apart tracks defines a first axis which extendslongitudinally relative to the pair of spaced apart tracks. The pair ofspaced apart tracks defines a second axis which extends latitudinallyrelative to the pair of spaced apart tracks. The pair of spaced aparttracks provides a course for back and fourth linear movement parallel tothe first axis. The object support assembly is linearly movable parallelto the first axis and the second axis.

The ability of the object support assembly to move parallel to thesecond axis is enabled by a plate that is coupled to the pair of spacedapart tracks. The plate may include four brackets, wherein two bracketsare coupled to each of the spaced apart tracks. The brackets of theplate enable the plate to move linearly and parallel to the first axis.The plate is also supported by the pair of spaced apart tracks that aresupported by the base. On top of the plate there is a track that isparallel to the second axis. The object support assembly is coupled tothe track on the top surface of the plate. The track on the top surfaceof the plate facilitates linear movement parallel to the second axis.The linear movement parallel to the first axis is independent of thelinear movement parallel to the second axis and vice versa. The objectsupport assembly which is coupled to the track on top of the plate isconfigured to linearly move parallel to the first axis and the secondaxis.

The object support assembly defines a third axis which may extendvertically from the center of the object support assembly. The thirdaxis is orthogonal to both the first axis and the second axis. Theobject support plate is configured to rotate about the third axis.Therefore, the object support plate may move parallel to the first axisand the second axis in addition to rotating about the third axis.

The motion control apparatus includes a fourth axis defined by thescanner track. In particular, the fourth axis extends longitudinallyrelative to the scanner track. The fourth axis is also parallel to thethird axis. The scanner is configured to linearly move along the scannertrack and parallel to the fourth axis. The linear movement of thescanner is independent of the movement of the object support plate withrespect to the first three axes.

The motion control apparatus includes a fifth axis extending from thescanner in a manner which is parallel to the second axis. The scanner isconfigured to pivot about the fifth axis. The motion control apparatusincludes a sixth axis defined by a line of sight associated with thescanner. The scanner line of sight corresponds to a linear axis adjacentto the direction in which a camera associated with the scanner isprojected towards. As a result, the sixth axis is variable dependingupon where the scanner is projected towards. The scanner is configuredto rotate about the sixth axis.

The six axis motion control apparatus may also include a controller formoving the object support assembly about the first axis, the second axisand the third axis. Additionally, the controller is configured to movethe scanner about the fourth axis, the fifth axis and the sixth axis. Asoftware program implemented on a computer in communication with themotion control apparatus to instruct the controller to move the objectsupport assembly and the scanner in accordance with an objectmeasurement plan.

In a second embodiment, a six axis motion control apparatus is provided.The motion control apparatus includes a frame used to support thevarious tracks associated with the scanning and measuring of an object.The motion control apparatus includes a pair of intersecting trackscoupled to the frame. The pair of intersecting tracks form a cross orT-shape. The scanner of the motion control apparatus is coupled to atleast one of the intersecting tracks. The scanner is linearly moveablein at least two axes defined by the pair of intersecting tracks.

The pair of intersecting tracks of the motion control apparatus definesa first axis extending latitudinally and a second axis extendinglongitudinally. One of the tracks from the pair of intersecting tracksis configured for linear movement parallel to the first axis. As aresult, the scanner is also movable parallel to the first axis. Thescanner includes an attachment means used to slide the scannervertically parallel to the second axis. The attachment means connectsthe scanner to one of the tracks from the pair of intersecting tracks.

The motion control apparatus also includes an object support assemblycoupled to the frame. The object support assembly is used to secure theobject to be scanned and measured. The object support assembly islinearly movable along a third axis. In addition to the object supportassembly moving linearly along the third axis, the object supportassembly is rotatable about a fourth axis. A pivoting member mounted tothe object support assembly may be pivotable about a fifth axis. Arotary drive bracket may be mounted to the pivoting member. The objectto be scanned may be mounted to the rotary drive bracket upon which theobject may be rotated about a sixth axis defined by the rotary drivebracket.

In another embodiment, a method for non-contact three dimensionalscanning of a surface of an object is provided. The method uses a sixaxis motion control apparatus having an object support assembly. Theobject support assembly is configured to support the object to bescanned. The object support assembly is coupled to a track for carryingthe object parallel to the track. The motion control apparatus alsoincludes a scanner for scanning and measuring the object. The methodbegins by receiving the object to be scanned on the object supportassembly. The method continues with the selection of a measurement plan.The measurement plan corresponds to a particular object to be scannedand maybe thought of as a set of instructions for automated maneuveringof the motion control apparatus relative to six different axes. Theobject is then moved to a plurality of positions with respect to thefirst through sixth axes. The object is scanned with respect to theplurality of positions. The method may conclude with the scanning andmeasuring with respect to each scanner position for the plurality ofpositions. The measurement plan used may be based upon a non-automatedscan of the object using the motion control apparatus. The non-automatedscan of the object is recorded on a computer in communication with theapparatus to facilitate the future scanning and measurement of asubstantially similar object.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the various embodimentsdisclosed herein will be better understood with respect to the followingdescription and drawings, in which like numbers refer to like partsthroughout, and in which:

FIG. 1 is a perspective view of a six axis motion control apparatus;

FIG. 2 is an aerial view of the six axis motion control apparatus ofFIG. 1;

FIG. 3 is a side view of the six axis motion control apparatus of FIG.1;

FIG. 4 is a frontal view of the six axis motion control apparatus ofFIG. 1;

FIG. 5 is a perspective view of a volumetric scanner and a scannersupport assembly;

FIG. 6 is a perspective view of an object support assembly;

FIG. 7 is a perspective view of a second embodiment of the six axismotion control apparatus;

FIG. 8 is a side view of the six axis motion control apparatus of FIG.7;

FIG. 9 is a frontal view of a scanner track of the six axis motioncontrol apparatus of FIG. 7; and

FIG. 10 is a side view of the object support assembly of the six axismotion control apparatus of FIG. 7.

DETAILED DESCRIPTION

The above description is given by way of example, and not limitation.Given the above disclosure, one skilled in the art could devisevariations that are within the scope and spirit of the inventiondisclosed herein, including various ways of constructing a motioncontrol apparatus for non-contact three dimensional scanning of asurface of an object. Further, the various features of the embodimentsdisclosed herein can be used alone, or in varying combinations with eachother and are not intended to be limited to the specific combinationdescribed herein. Thus, the scope of the claims is not to be limited bythe illustrated embodiments.

A motion control apparatus for non-contact three dimensional scanningfor use in various applications, including metrology, reference pointsystem (RPS) registration, best-fit registration, first articleinspection, automation, reverse engineering, and dimensionalverification is disclosed. Objects to be scanned are mounted on a tablethat is movable relative to three different axes. A scanner is alsoprovided which is movable relative to three different axes.

Referring now to FIG. 1, a six axis motion control apparatus 10constructed in accordance with a first embodiment of the apparatus isprovided. The motion control apparatus 10 is used to move an object 36or work piece to be scanned with respect to a white light volumetricscanner 44. Additionally, the scanner 44 may be moved to capture theobject 36 from various perspectives to enable a more comprehensive scanof the object 36. The apparatus 10 is configured for linear motion,rotational motion, and pivoting about a plurality of axes. The apparatus10 includes a base 12. The base 12 may be formed in the shape of arectangular box. However, the base 12 is not limited to a rectangularshape and may encompass a variety of different shapes and sizes. Aplurality of castors (not shown) may also be coupled to the underside ofthe base 12 so that the apparatus 10 is portable. The base 12 is used tosupport the various parts that facilitate movement of the object 36 andthe white light volumetric scanner 44. The scanner 44 may be an ATOS 3DScanner as manufactured by GOM Optical Measuring Techniques incorporatedherein by reference. However, other three dimensional white lightvolumetric scanners may be used with the six axis motion controlapparatus 10. Moreover, other types of scanners may be used that areknown in the art or developed in the future.

Attached to a top portion of the base 12 is a pair of spaced aparttracks 14 and 16. The pair of spaced apart tracks 14 and 16 is disposedgenerally parallel to each other. The pair of spaced apart tracks 14 and16 may each include a slot for receiving a sliding bracket 20 having arib extending from the underside to facilitate linear movement along thepair of spaced apart tracks 14 and 16. The pair of spaced apart tracks14 and 16 attached to the top portion of the base 12 is designed toallow for linear movement bi-directionally along the tracks 14 and 16. Amotor 18 may be coupled to the tracks 14 and 16 to provide mechanicalpower to move an item placed on the pair of spaced apart tracks 14 and16 linearly. The pair of spaced apart tracks 14 and 16 may be coupled tovarious mechanisms that provide motion control such as the motor 18 andtiming belt for traversal of an object support assembly 28 (see FIGS. 3and 6) along axis 15 (see FIG. 2). It is also contemplated that motioncontrol can be achieved through other means known in the art ordeveloped in the future. For example, the tracks 14 and 16 mayalternatively have other mechanisms that control motion such as linearactuator, lead screws, pneumatic mechanisms, hydraulic mechanisms,pulleys, etc. Other motors and timing belts and motion controlmechanisms are discussed herein in relation to the other aspects of themotion control apparatus 10. It is contemplated that other motioncontrol mechanisms may be utilized in those situations such as linearactuators, lead screws, pneumatic mechanisms, hydraulic mechanisms,pulleys, etc.

Referring to FIG. 2, the pair of spaced apart tracks 14 and 16 definetwo separate axes 15, 17. Extending longitudinally from the pair ofspaced apart tracks 14 and 16 is a first axis 15. Extendinglatitudinally from the pair of spaced apart tracks 14 and 16 is a secondaxis 17. The first axis 15 and the second axis 17 are perpendicular toeach other. Movement along the pair of spaced apart tracks 14 and 16 islinear and parallel to the first axis 15. In this regard, the object 36that is supported by the base 12 is moved parallel to the first axis 15.It is also contemplated that the base 12 may include only a single trackattached to the base 12 that provides for linear movement parallel tothe first axis 15.

Referring to FIG. 6, a plate 21 is provided. The plate 21 as shown isrectangular; however, other shapes and sizes may be used to form theplate 21 that is placed on the pair of spaced apart tracks 14 and 16.The rectangular plate 21 includes four sliding brackets 20 coupled toeach corner of the rectangular plate 21. Each sliding bracket 20 isconfigured to be received by the pair of spaced apart tracks 14 and 16.The underside of each sliding bracket 20 may include an extension thatis placed in contact with the pair of spaced apart tracks 14 and 16 forfacilitating linear movement of the rectangular plate 21 parallel to thefirst axis 15 (see FIG. 2). The pair of spaced apart tracks 14 and 16are configured to slidably receive each sliding bracket 20 coupled tothe plate 21. As a result, the plate 21 is moved parallel to the firstaxis 15 through operation of the motor 18 (see FIG. 1) and other motioncontrol mechanisms (e.g., timing belt, lead screw, etc).

On top of the plate 21 is an object support track 24 (see FIG. 6). Theobject support track 24 is generally parallel to the second axis 17 (seeFIG. 2) and configured to receive an object support assembly 28 (seeFIGS. 3 and 6) for linear movement along a longitudinal direction of theobject support track 24 and parallel to the second axis 17 under thepower of a motor 29 (see FIG. 6) and other motion control mechanism suchas timing belt, lead screw, linear actuator, etc. Adjacent the objectsupport track 24 on the top surface of the plate 21 is a flexibleconduit 26 (see FIG. 6) coupled to the object support assembly 28 forhousing cables and the like. The object support assembly 28 isconfigured to move parallel to the second axis 17 independent of anylinear movement of the plate 21 parallel to the first axis 15.

Referring now to FIG. 3, the object support assembly 28 includes arotary drive bracket 30 coupled to the object support track 24. Therotary drive bracket 30 is powered by a motor 32. It is alsocontemplated that the rotary drive bracket 30 may be powered throughother power transmission means such as pneumatic, hydraulic, gears,pulleys, etc. Attached to the top of the rotary drive bracket 30 andalso included in the object support assembly 28 is an object supportplate 34. The object support plate 34 may be configured in many shapesand sizes. In FIG. 3, the object support plate 34 is circular. Therotary drive bracket 30 may include a central aperture. The centralaperture is adapted to receive a shaft (not shown) formed on the underside of the object support plate 34. The shaft may be connected to agear mechanism, for example, to enable the rotary drive bracket 30 torotate about a third axis 19. The third axis 19 may be defined by therotary drive bracket 30 and extend vertically from the object supportplate 34. Such a configuration enables rotary movement of the object 36to be scanned. The rotational movement of the object support plate 34 isindependent of the linear movement of the object support assembly 28with respect to the first axis 15 and the second axis 17.

The third axis 19 (see FIG. 3) is orthogonal to the first axis 15 andthe second axis 17. The object support plate 34 is configured to rotateabout the third axis 19, as shown by arrow 31 (see FIG. 3). The objectsupport assembly 28 which includes the object support plate 34 coupledto the rotary drive bracket 30 powered by the motor 32, allows forrotation about the third axis 19. The object 36 placed on the objectsupport plate 34 may be rotated between 0 and 360 degrees. Referringback to FIG. 1, when the object 36 to be scanned is placed on top of theobject support plate 34 of the object support assembly 28, the object 36may be moved relative to the first and second axes 15, 17 and rotateabout the third axis 19. Also, the object 36 on the object support plate34 can be traversed relative to a single axis independent of the otheraxes. Thus, the object 36 placed on the object support plate 34 may movealong two linear axes 15, 17 and rotate about the third axis 19 forscanning the object 36 at a plurality of views. The object 36 on theobject support plate 34 may be scanned and measured while movingparallel to the first axis 15 and parallel to the second axis 17, androtating about the third axis 19.

The motion control apparatus 10 also includes a scanner track 38 and ascanner track support 40, as shown in FIGS. 1 and 3. The scanner tracksupport 40 is coupled to the base 12 of the motion control apparatus 10.The scanner track 38 may be attached to the scanner track support 40using a series of brackets, screws, or other well known affixing means.The scanner track support 40 is used to vertically support the scannertrack 38. The scanner track 38 has a proximal end and a distal end. Theproximal end of the scanner track 38 may be disposed within the base 12of the motion control apparatus 10, as shown in FIG. 1. The distal endof the scanner track 38 extends away from the base 12. The scanner track38 includes slots similar to those described for the pair of spacedapart tracks 14 and 16 described above. The slots are configured toreceive an attachment means associated with the scanner 44 to enablelinear movement of the scanner 44. The scanner track 38 and the scannertrack support 40 are removable from the base 12 portion of the motioncontrol apparatus 10. The ability to remove both the scanner track 38and the scanner track support 40 enhances the portability of the motioncontrol apparatus 10.

Referring again to FIG. 3, the scanner track 38 defines a fourth axis 23extending longitudinally with respect to the scanner track 38. Thefourth axis 23 is parallel to the third axis 19. The scanner track 38 isconfigured to facilitate linear movement of a scanner support 50parallel to the fourth axis 23 via motor 51 and other motion controlmechanisms such as a timing belt, lead screw, linear actuator, etc. Thescanner support 50 is used to attach the scanner 44 to the scanner track38. The scanner support 50 may be attached to a sliding bracket havingan extension formed on the underside of the sliding bracket to securethe scanner support 50 to the scanner track 38. Coupled to the scannersupport 50 is a flexible conduit 42 which holds cables and the like.

Referring now to FIGS. 3 and 5, the scanner 44 and the scanner support50 are provided in further detail. The scanner support 50 is generallyformed in a U-shape wherein the closed portion of the U-shaped scannersupport 50 is attached to the scanner track 38 typically using a slidingbracket. Within the scanner support 50 is another U-shaped bracket 54.The U-shaped bracket 54 is configured to pivot relative to the scannersupport 50 which allows the scanner 44 to pivot about the fifth axis 25under the power of motor 56. Other motion control mechanisms may be usedto pivot the scanner 44 about the fifth axis 25 that are known in theart or developed in the future. By way of example and not limitation,the bracket 54 may be pivoted to the support 50 pneumatically,hydraulically, etc. The U-shaped bracket 54 pivots about the fifth axis25, as shown by arrow 57 (see FIG. 5). The scanner 44 is positionedbetween the tines of the U-shaped bracket 54 and the tines of thescanner support 50. The base portion or the closed potion of theU-shaped bracket 54 is attached to the top portion of the scanner 44with a rotary bracket 61 (see FIG. 5) which allows for the scanner 44 tobe rotated about a sixth axis 27, as shown by arrow 59 (see FIG. 5). Themotor 56 may be coupled to the outer portion of the scanner support 50to provide the mechanical power being translated from the motor 56 tothe U-shaped bracket 54 in order for the bracket 54 to pivot about thefifth axis 25. Another motor 55 may also be coupled to the base portionof the U-shaped bracket 54 to facilitate the rotary movement of thescanner 44 within the U-shaped bracket 54 about the sixth axis 27. Themotor 55 may be used in conjunction with other motion control mechanismsthat are known in the art or developed in the future. Additionally, themotor 56 may be replaced with other means for providing power such aspneumatic systems, hydraulic systems, etc.

Three dimensional scanners such as scanner 44 provide significantmeasuring results that are particularly a great benefit for processanalysis. The scanner 44 is based on the principle of triangulation. Asensor unit 53 projects different fringe patterns onto the object 36 tobe measured. These patterns are then recorded by two cameras 46 and 48.The sensor unit 53 of the scanner 44 includes a line of sight that isdirected at the object 36 to be scanned or measured. The line of sightof the sensor unit 53 of the scanner 44 defines the sixth axis 27,wherein the cameras 46 and 48 are configured to rotate about the sixthaxis 27, as shown by arrow 59 (see FIG. 5). Although only two camerasare shown, the scanner 44 may have additional cameras (e.g., three ormore cameras). The scanner 44 may be a volumetric scanner such as awhite light volumetric scanner.

Referring to FIGS. 4 and 5, the fifth axis 25 extending from the pivotpoint of the bracket 54 to the scanner support 50 is parallel to thesecond axis 17 (see FIG. 2). The scanner 44 moves linearly and parallelto the fourth axis 23 (see FIG. 3) as a result of being coupled to thescanner track 38 via the scanner support 50. As discussed above, thescanner 44 is configured to rotate about the sixth axis 27 independentof movement parallel to the fourth axis 23. This allows the scanner 44to scan objects in the scanner's line of sight while rotating between 0to 360 degrees to get a more comprehensive scan of the object 36 or thework piece. In addition to the linear movement parallel to the fourthaxis 23 and the rotation about the sixth axis 27, the scanner 44 isconfigured to pivot about the fifth axis 25. In this regard, the scanner44 is movable with respect to three different axes. The scanner 44 moveslinearly along the fourth axis 23, is rotatable about the fifth axis 25,and pivotable about a sixth axis 27. The motion control apparatus 10provides for six axis motion control. The object support plate 34 ismovable with respect to the first three axes 15, 17, 19 and the scanner44 is movable with respect to the fourth, fifth, and sixth axes 23, 25,27. The advantage being that the object 36 to be scanned is scannablefrom various perspectives relative to the six axes described formeasurement of the object 36.

Referring now to FIG. 7, a second embodiment of the six axis motioncontrol apparatus 100 is provided. The motion control apparatus 100includes a frame 102. The frame 102 may be constructed from variousmaterials including metal or wood by way of example. The frame 102 maybe formed in the shape of a rectangular box. It is contemplated that theframe 102 may be constructed in a variety of shapes and sizes. Attachedto the bottom of the frame 102 is a plurality of castors 112, providingportability to the frame 102 of the apparatus 100.

Referring now to FIG. 9, a first track 104 and a second track 106 areprovided. The first track 104 is coupled to opposing bars comprising oneside of the frame 102. The first track 104 defines a first axis 128extending latitudinally. The first track 104 may include a slot orplurality of slots for receiving an extension part from the underside ofthe second track 106. The extension on the underside of the second track106 is configured to attach to the slot or slots of the first track 104,such that the second track 106 is securely coupled to the first track104. The second track 106 may move linearly along the first track 104and parallel to the first axis 128 under the power of motor 129 andmotion control mechanisms such as a timing belt, lead screw, linearactuators, etc. The first track 104 and the second track 106 intersectand are perpendicular to each other. The second track 106 defines asecond axis 126 extending longitudinally. The second axis 126 isorthogonal to the first axis 128. The second track 106 may include asliding bracket 107 configured to receive a scanner support assembly 108(see FIG. 8). The sliding bracket 107 is configured to move parallel tothe second axis 126 under the power of motor 131 and motion controlmechanisms such as a timing belt, lead screw, linear actuator, etc.

Referring to FIG. 8, the scanner support assembly 108 is coupled to thesecond track 106 via the sliding bracket 107. The scanner supportassembly 108 moves parallel to the second axis 126 (see FIG. 9). Also,the scanner support assembly 108 may move parallel to the first axis 128(see FIG. 9). This configuration provides for linear movement of thescanner 110 parallel to two different axes. As a result, the scanner 110has two degrees of freedom with respect to linear motion.

Referring now to FIGS. 7, 8 and 10, an object support assembly 120 isshown. A third track 114 may be attached to the object support assembly120. The object support assembly 120 is configured to receive an object122 (see FIG. 8) for scanning and measurement. The third track 114 iscoupled to the frame 102 and orthogonal to both the first track 104 (seeFIG. 9) and the second track 106 (see FIG. 9). The third track 114defines a third axis 136 (see FIG. 8) extending longitudinally relativeto the third track 114. The third axis 136 extends longitudinallyrelative to the third track 114. The third axis 136 (see FIG. 8) isorthogonal to the first two axes 126 and 128 (see FIG. 9). The thirdtrack 114 may include a slot or a plurality of slots to receive anextension from the underside of a rotary drive bracket 118 (see FIG. 8)for rotating the object support assembly 120 about a fourth axis 132(see FIG. 10). The object support assembly 120 may move longitudinallyalong the third axis 136 under power of motor 116 and other motioncontrol mechanisms such as timing belt, lead screw, linear actuator,etc.

The rotary drive bracket 118 may rotate the object support assembly 120about the fourth axis 132 (see FIG. 10) which extends vertically fromthe rotary drive bracket 118. The fourth axis 132 may be orthogonal tothe third axis 136 (see FIG. 8) and parallel to the second axis 126 (seeFIG. 9). The rotary drive bracket 118 may receive power to rotate theobject support assembly under power of motor 121 (see FIG. 10) or otherpower transmission means for providing rotation known in the art ordeveloped in the future. It is contemplated that other well knownmechanisms may be used to provide mechanical power for rotation of therotary drive bracket 118 and linear movement of the object supportassembly 120 along the third axis 136.

The object support assembly 120 also includes a pivoting member 124 (seeFIGS. 7, 8 and 10) pivotally coupled to the object support assembly 120.The pivoting member 124 defines a fifth axis 134 (see FIG. 8). Thepivoting member 124 is configured to pivot about the fifth axis 134under the power of motor 133 (see FIG. 10) or other power transmissionmeans known in the art or developed in the future. Rotation of thepivoting member 124 is shown by arrow 148 in FIGS. 7 and 8. A secondrotary drive bracket 138 may be mounted to the pivoting member 124, asshown in FIG. 10. This permits the object 122 to be rotated about axis140 (see FIG. 10). Rotation about axis 140 is shown by arrow 142 inFIGS. 7 and 10 and rotation of the support assembly 120 about axis 132is shown by arrow 144 shown in FIGS. 7 and 10. Similar to the rotarydrive bracket 118, the rotary drive bracket 138 mounted to the pivotingmember 124 may receive power to rotate the object 122 under power ofmotor 146 (see FIG. 10) or other power transmission means for providingrotation known in the art or developed in the future. Therefore, whenthe object 122 or work piece to be scanned and measured is secured tothe rotary drive bracket 138, the object 122 may be moved relative tofour different axes 136, 132, 134, 140. The object support assembly 120may move linearly parallel to the third axis 136, rotate about thefourth axis 132, pivot about the fifth axis 134 and rotate about thesixth axis 140. The scanner 110 moves about two separate axes. Thisallows the motion control apparatus 100 to scan and measure objects 122with respect to six different axes.

The motion control apparatuses 10, 100 provides an automated measurementprocess for objects to be scanned. The automated measurement process maybe based on a measurement plan. The measurement plan may be configuredby manually recording operation of the motion control apparatuses 10,100 with respect to a particular object that is being measured and thescanner. After the measurement plan is stored in the computer, themotion control apparatuses 10, 100 may be controlled automatically basedon the precise coordinates recorded within the measurement plan. Themotion control apparatuses 10, 100 increases the number of partsscannable per hour. The motion control apparatuses 10, 100 may repeatthe measurement and scanning process without the necessary repetition ofmanual control by an operator. The motion control apparatuses 10, 100measures each part in precisely the same way by using the repetitiveprocess, eliminating the variability of different operators. The motioncontrol apparatuses 10, 100 allows for a more comprehensive inspectionof the object 36, 122 to be scanned.

In relation to both embodiments, the object to be scanned may be securedto the object support plate 34 or the rotary drive bracket 138. Also, inboth embodiments, the object to be scanned and the scanner may beoriented at various angles with a joystick 150 (see FIGS. 1 and 7). Thejoystick 150 may have two handles 152 a, b. The handle 152 a may be inelectronic communication with motion control apparatuses 10, 100 formanipulating orientation of the object to be scanned as discussed above.Similarly, the handle 152 b may be in electronic communication with themotion control apparatuses 10, 100 for manipulating orientation of thescanner 44, 110. The object and scanner are placed at variousorientations with respect to each other such that the scanner is capableof scanning the object at a plurality of desired views. It is alsocontemplated that the joystick may be replaced with a touch pad, mouseor other type of controller.

The apparatuses 10, 100 discussed herein may also have a plurality ofsensors operative to determine the exact position of the object to besensed and the scanner by determining the position of the variousbrackets and supports for supporting the object and the scanner. Thesensors may be proximity sensors, wheel sensors, position sensors orother sensors that are known in the art or developed in the future. Inparticular, for the first embodiment, a first sensor may sense theposition of the object support plate 34 along the first axis 15. Asecond sensor may sense the position of the object support plate 34along the second axis 17. A third sensor may sense an angular positionof the object support plate 34. A fourth sensor may sense the positionof the scanner along the fourth axis 23. A fifth sensor may sense theangular position of the bracket 54 with respect to the support 50. Asixth sensor may sense the angular position of the scanner with respectto the bracket 54. For the second embodiment, six sensors may sense thelinear and angular positions of the various components. The sensors maycommunicate with a computer and provide positional information to thecomputer for dimensional analysis of the object and other functions.

Initially, the apparatuses 10, 100 may be programmed to scan an object36, 122. The object may initially be secured to the object support plate34 or the rotary drive bracket 138. The operator manipulates the object36, 122 with the handle 152 a of the joystick 150 such that the object36, 122 is adjacent to the scanner or is in a scannable position. Theoperator also manipulates the scanner 44, 110 with the handle 152 b ofthe joystick 150 such that the scanner 44, 100 is adjacent to the object36, 122 to be scanned. In summary, after the object is attached to theobject support plate 34 or the rotary drive bracket, the operatortranslates the object and the scanner to an initial starting position.

The operator moves the object and the scanner with respect to each othersuch that the scanner can take different views of the object beingscanned and to take various dimensional readings off of the object beingscanned. With each step, the positions of the object and the scanner areknown due to the sensors and recorded in the computer. The informationobtained from the scanner to determine the dimension of the object isalso associated with the positional information of the object andscanner and stored for analysis. The operator continues the process byfurther manipulating the object and the scanner into various positionsto take multiple dimensional readings of the object by the scanner at aplurality of different views.

The information obtained through the scanning process described abovemay be analyzed to determine the dimensions of the scanned object. Thescanned dimensions of the scanned object may be compared to computeraided drafting based dimensions of the object to determine whether thescanned object is within tolerance or is to be rejected. The operatormay complete the scanning process for a sample of objects in aparticular lot or scan every object in the lot. The apparatus allows forrecording of the various positions of the scanner and the object duringthe scanning process. Accordingly, the operator may mount the object tothe object support plate 34 or the rotary drive bracket 138, then allowthe programmed scanning process to repeat the previously recorded stepsperformed manually by the operator.

Alternatively, the object to be scanned may be the “standard” to which aproduction run of the object is compared. The first scan of the standardobject may determine the dimensions of the standard object. Subsequentobjects may be compared to the scanned dimensions of the scanned objecteither manually or automatically by allowing the apparatus to run thepreprogrammed steps manually programmed in by the operator.

It is also contemplated that the initial positions of the object to bescanned and the scanner may be preprogrammed such that the operator needonly mount the object to the object support plate 34 or the rotary drivebracket 138.

1-20. (canceled)
 21. A method of non-contact scanning a surface of anobject with a motion control apparatus, the method comprising the stepsof: mounting the object to an object support member of the motioncontrol apparatus; manipulating the spatial relationship between a noncontact scanner and the object support member for non contact scanningof the surface of the object wherein the non contact scanner is disposedadjacent to the object support member, the manipulating step comprisingthe steps of: traversing the object support member linearly along afirst axis and rotateably about a second axis, third axis and a fourthaxis; traversing the non contact scanner along a straight fifth axisparallel to the second axis and linearly along a sixth axis.
 22. Themethod of claim 21 wherein the non contact scanner is a volumetricscanner.
 23. A method of non-contact scanning a surface of an objectwith a motion control apparatus, the method comprising the steps of:mounting the object to an object support member of the motion controlapparatus; manipulating the spatial relationship between a non contactscanner and the object support member for non contact scanning of thesurface of the object wherein the non contact scanner is disposedadjacent to the object support member, the manipulating step comprisingthe steps of: rotating the object support member about a rotationalaxis; linearly traversing the non contact scanner along a straightlinear traversal axis which is parallel to the rotational axis.
 24. Themethod of claim 23 wherein the non contact scanner is a volumetricscanner.
 25. The method of claim 23 further comprising the steps oftraversing the object support member along two orthogonal lineartraversal axes.
 26. The method of claim 25 wherein the two orthogonallinear traversal axes is orthogonal to the rotational axis of the objectsupport member.
 27. The method of claim 25 further comprising the stepsof rotating the non contact scanner about two orthogonal axes.
 28. Amotion control apparatus for non-contact scanning of a surface of anobject, the apparatus comprising: an object support member forsupporting the object, the object support member rotatable about atleast one axis defined by the object support member and linearlytraversable along at least one straight longitudinal axis defined by theobject support member; a non contact scanner for non contact scanning ofthe surface of the object, the scanner positioned adjacent to the objectsupport member, the scanner being linearly traversable along at leastone straight linear axis defined by the scanner; wherein a total numberof rotational axes of the object support member and the non contactscanner is at least three, and a total number of linear traversal axesof the object support member and the scanner is at least three.
 29. Theapparatus of claim 28 wherein one straight linear traversal axis of thenon contact scanner is parallel to one rotational axis of the objectsupport member.
 30. The apparatus of claim 28 wherein the non contactscanner is a volumetric scanner.